Concrete tile system and method of manufacture

ABSTRACT

Tile panel assemblies and systems of manufacturing and installing said tile panels. The tile panels of the subject invention can be used as a covering for walls, roofs, siding, etc. on a variety of structures. In one embodiment, the tiles are manufactured of a lightweight concrete having sufficient strength to withstand extreme weather and wind conditions, as well as normal handling or foot traffic required for installation and maintenance. In a further embodiment, the tiles of the subject invention comprise insulation, preferably foam, affixed thereto. The tile panels are constructed so as to present an overlapping configuration and selectively interlocking systems that provide resistance to negative pressure wind uplifting and enhanced insulation properties. Also disclosed is a tile bracket apparatus that can secure the leading edge of a tile to prevent wind-uplift.

CROSS-REFERENCE TO RELATED APPLICATION(S)

The present application claims the benefit of U.S. Provisionalapplication Ser. No. 60/724,831, filed Oct. 7, 2005, which is herebyincorporated by reference herein in its entirety, including any figures,tables, or drawings.

BACKGROUND OF THE INVENTION

The subject invention relates to a selectively interlocking tilecovering system for homes, buildings, or other structures. Specifically,the subject invention relates to a four-sided interlocking tile panelcovering system that utilizes an insulated lightweight concrete tile.The subject invention further relates to a method for manufacturing theconcrete tiles and means for utilizing the tiles as a roof coveringsystem.

In many parts of the world, concrete or clay tiles are utilized onhomes, buildings and an assortment of other structures. In theirsimplest design, overlapping tiles are positioned on an underlyingsupport system. When used for roofing, the tiles are placed on the roofdecking or other support system. Such installations are usually notoverly secured and are easily destroyed under extreme environmentalconditions. Such tile systems are especially vulnerable during high windconditions, for example during hurricanes. It is not uncommon for highwinds passing or crossing over the tiles to produce a negative pressureor Bernoulli effect, whereby air space under unsecured or ineffectivelysecured tiles is evacuated by high winds causing tiles to be more easilyraised up from underlying roofing structure and displaced, or completelyremoved from a roof. Tile roofing systems have been devised that aremore secure, but such systems often require complicated means formanufacturing and installing tiles, see for example U.S. Pat. Nos.5,743,059 and 6,604,336; or for securing them to the underlying roofstructure, see for example U.S. Pat. Nos. 5,323,580; 5,522,187; and5,921,045.

In addition, it is well-known in the art that insulating the roof and/orwalls of a structure can increase energy efficiency. But, there havebeen few options available that provide direct roofing insulation thatis cost-effective and easily installed. See for example U.S. Pat. Nos.5,062,250; 5,069,950; and 5,787,668.

The subject invention addresses these issues by providing a roofing tilepanel and a system of installation that creates a roof covering havinghigh wind resistance, as well as insulating properties. The tiles of thesubject invention are also relatively easy to manufacture and install,making them a cost-effective alternative to standard roofing tiles. Alsoprovided in the subject application is a roofing accessory that iseasily installed and can increase the wind resistance of existing tiledesigns.

BRIEF SUMMARY

The subject invention pertains to tile panels, as well as systems ofmanufacturing and installing said tile panels. The tile panels of thesubject invention are particularly well-suited as a roof coveringsystem. However, a person with skill in the art after reviewing thefollowing description will recognize a diverse number of other uses forthe tile panels and teachings of the subject invention, including forexample, as a covering for walls, siding, etc.

In one embodiment, the tiles are manufactured of a lightweight concretehaving sufficient strength to withstand extreme weather and windconditions, as well as normal handling or foot traffic often requiredfor installation and maintenance, especially when utilized as a roofcovering. In a further embodiment, the subject invention provides a tilepanel assembly wherein the tile panels may comprise insulation affixedthereto. The tile panels are constructed so as to present an overlappingconfiguration that can, preferably, interlock on all four sides toprovide resistance to negative pressure wind uplifting. In a stillfurther embodiment, the tile panels utilize a backing material to lendadditional strength to the tile panels and, further, to reduce theamount of air space between the underlying roof structure and thepanels. For example, a foam, or foam-like, material can be utilized tofill the space under the tiles and reduce air space. Reduction of theavailable air space can further reduce or eliminate the effects of winduplift caused by negative pressure, i.e., the Bernoulli effect, and canadditionally provide insulation properties to the tiles.

In certain embodiments, the backing material can also be formed toprovide a four-sided interlocking tile system that holds and/orstabilizes tile panels against each other and the underlying roofstructure(s), as well as reducing the amount of surrounding air space.However, in certain alternative embodiments, the sheathing surface canbe formed, according to the subject invention, to provide a four-sidedinterlocking tile system also capable of holding and/or stabilizing tilepanels against each other and the underlying roof structure(s).

By way of example, one or more edges of the tiles are cut, shaped orotherwise formed to provide a selectively-interlocking covering, similarto, for example, a mortise and tenon arrangement. In a furtherembodiment, the leading edge of a tile of the subject invention isformed to provide an interlock channel, or mortise-like opening, and thetrailing edge is formed to provide an insertion edge, or tenon-likeextension. Thus, in this embodiment of the roofing system of the subjectinvention, the insertion edge, formed at or near the trailing edge ofone tile, engages the interlock channel formed at or near the leadingedge of another higher adjacent tile, such that the leading edge of thehigher tile overlaps the trailing edge of the lower tile. In preferredembodiments, the leading edge overlaps the trailing edge and covers themounting hole of the first tile, minimizing its exposure to theelements. The means for interlocking the leading edge of one tile withthe trailing edge of another, lower tile is located higher (up-roof)than the mounting hole and fastener that are proximal to the trailingedge of the lower tile panel.

In an embodiment, the tile panels, once interlocked, can be attached toan underlying roofing structure, or roof decking utilizing standardroofing nails or screws. The tile system of the subject invention alsoprovides specialized tiles for covering roof apex points, hip lines, anddrip edges.

Alternative embodiments of the subject invention utilize tiles that havea mortise and tenon (also referred to as tongue-and-groove) type, orsimilar, configuration. In this embodiment, the leading edge of a tileis formed with at least one protrusion or tenon and the trailing edge ofone, or conversely two, tiles form at least one corresponding opening ormortise. In such embodiments, the tenon(s) of a first tile can bepositioned within the mortise(s) of one or more second tile(s), suchthat the leading edge of the first tile overlaps the trailing edge ofthe second tile(s).

Still further alternative embodiments of the subject application providetile brackets that can be affixed to or incorporated into the uppersurface of existing prior art tiles, or the novel tiles of the subjectinvention. The brackets secure the leading edge of tiles to providegreater wind resistance. In such embodiments, one or more tile bracketscan be affixed to or incorporated into the upper surface of a firsttile, at or near its trailing edge. A second tile is positioned tooverlap the trailing edge of the first tile such that the leading edgeof the second tile is received by the one or more tile bracketspositioned on the trailing edge of the first tile. The tile bracket armis generally designed to extend over the leading edge of the second tileto prevent it from being lifted once positioned in the tile bracket(s).

The various embodiments of the subject invention are designed to secureat least the leading edges of installed tiles and, in preferredembodiments, the side and/or trailing edges as well, to preventwind-uplift and/or the Bernoulli Effect from removing or breaking thetiles during high wind conditions. The more secure the edges of thetiles, and the less air space under the tiles, the less likely the tileswill be lifted off or broken off by high winds.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that a more precise understanding of the above recitedinvention is obtained, a more particular description of the inventionbriefly described above will be rendered by reference to specificembodiments thereof that are illustrated in the appended drawings.Understanding that these drawings depict only typical embodiments of theinvention and are not therefore to be considered as limiting in scope,the invention will be described and explained with additionalspecificity and detail through the use of the accompanying drawings inwhich:

FIG. 1 is a perspective view of an embodiment of the subject inventionillustrating a barrel-style tile.

FIG. 2A is an end-view of the upwardly-curved side of a tile shown inFIG. 1.

FIG. 2B is an end-view of a flat tile embodiment of the subjectinvention.

FIG. 3A is an end-view of the downwardly-curved side of a tile shown inFIG. 1.

FIG. 3B is a bottom plan view of a flat tile embodiment of the subjectinvention.

FIG. 4 is a cross-section of a downwardly-curved section of the tileshown in FIG. 1.

FIG. 5 is a cross-section of an upwardly-curved section of the tileshown in FIG. 1.

FIG. 6A is a side-view of an alternative embodiment of the subjectinvention illustrating a flat-style tile.

FIG. 6B is an enlarged view of the connecting means and interlockingmechanism of an embodiment of the subject invention as shown in FIG. 6A.

FIG. 7A is an end-view of an embodiment of a crown panel that can beutilized with the subject invention.

FIG. 7B is a side-view of an embodiment of a crown panel that can beutilized with the subject invention.

FIG. 7C is a cross-section of a side-view of an embodiment of a ridgepanel that can be utilized with the subject invention.

FIG. 7D is a side view of an embodiment of the crown panels shown inFIGS. 7A, 7B, and 7C, illustrating how they can be interconnected.

FIG. 8A is a perspective view of an embodiment of a hip panel that canbe utilized with the subject invention.

FIG. 8B is a cross-section of a side-view of the embodiment of a hippanel shown in FIG. 8A.

FIG. 9 is a side-view of an embodiment of a drip panel that can beutilized with the subject invention.

FIG. 10 is a perspective view of the embodiment of a drip panel, asshown in FIG. 9.

FIG. 11 is a perspective view of an embodiment of a roof end panel thatcan be utilized with the subject invention.

FIG. 12A is a perspective view of an embodiment of a tenon and mortise(or tongue-and-groove) tile design that can be utilized with the subjectinvention. This embodiment illustrates a dove-tail configuration.

FIG. 12B is a view of FIG. 12A wherein the full configuration of thetenon and mortise (or tongue-and-groove) of this embodiment can be seen.

FIG. 12C is a perspective view of an alternative embodiment of a tenonand mortise (or tongue-and-groove) tile design that can be utilized withthe subject invention. This embodiment illustrates an alternatedove-tail configuration.

FIG. 12D is a view of FIG. 12C wherein the full configuration of thetenon and mortise (or tongue-and-groove) of this alternative embodimentcan be seen.

FIG. 13A is a perspective view a tile bracket embodiment of the subjectinvention.

FIG. 13B is a perspective view of an alternative embodiment of the tilebracket of the subject invention.

FIG. 14 is a cross-sectional side view of an alternative embodiment ofthe tile panel of the subject invention.

DETAILED DISCLOSURE

With reference to the attached figures, which show certain embodimentsof the subject invention, it can be seen that the subject inventionpertains to four-sided interlocking tile panels and systems forutilizing and installing the tile panels. One embodiment utilizes anoverlap interlocking system wherein an edge of one tile overlaps andinterlocks with an edge of another tile. A second embodiment utilizes atenon and mortise (or tongue-and-groove) mechanism wherein one or moretenons of one tile can interlock with one or more mortises formed by atleast one other tile. A third embodiment provides a tile bracketmechanism that can be affixed to a first tile so as to secure theleading edge of an overlapping second tile. The selectively-interlockingtile panel embodiments and the tile bracket mechanism will be discussedin detail below.

I. Overlap Interlocking Tile Panel

The Overlap Interlock tile panels of the subject invention can provideincreased durability and resistance to a variety of weather conditions,including extreme environmental events with high wind conditions. Thetiles are preferably manufactured from one or more lightweightconcretes, known in the art, which allows them to advantageously beutilized in a variety of construction areas, usually without additionalreinforcement of the underlying support system, for example a roofdecking. In addition, the tiles of the subject invention are reinforcedwith a backing material, for example a foam or foam-like material, thatprovides additional strength and insulating properties, as well asminimizing airspace beneath the tiles, lending them advantageouscharacteristics in high wind conditions. When installed, the tile panels10 of the subject invention are secured on all sides, wherein at leasttwo sides utilize a selectively interlocking system and at least twoother sides are secured by the overlap of adjacently positioned tiles.These features, combined with the backing material to minimize air spaceunder the tiles, can provide a high wind resistant four-sidedinterlocking roof cover. In preferred embodiments, the panels are rigid;the rigidity ideally being a characteristic conveyed by the materialused to make the sheathing surface, the backing material, or both ofthem.

For the purposes of this application only, the tile panels of thesubject invention are described as a roof covering. This descriptionshould not be construed as a limitation in practicing the subjectinvention.

With reference to the attached figures, which show certain embodimentsof the subject invention, it can be seen that the tile panels 10comprise a sheathing surface 12 that overlays a backing material. Thesheathing surface 12 can be manufactured from a variety of materials,including, but not limited to, various metals, plastics, glass, woods,as well as natural or petroleum-based products or any combinations orcomposites thereof, etc., as are well known and would be readilyapparent to those skilled in the art. In standard applications, tilesare usually manufactured from clay, concrete, or various composites orblends thereof, and such materials as those and others mentioned hereinabove may also be utilized in conjunction with the subject invention.Such tiles may also be reinforced with a variety of materials. However,standard clay or concrete, especially if reinforced, tends to be heavy,and may require additional reinforcement of roofing structure anddecking. Therefore, it may be preferable, but not required, to use alighter weight material.

In alternative embodiments, the sheathing surface 12 of the tile panelof the subject invention is manufactured from a lightweight concrete,for example, various cellular concrete products, or lightweightaggregate concretes, such as GRANCRETE®, or other similar products asare well known to those skilled in the art. In a further alternativeembodiment, a foaming agent may be incorporated into a concrete mix, asis also known in the art, to reduce weight, without adversely affectingthe strength of the concrete necessary for utilization with the subjectinvention.

The methods and techniques of manufacturing tiles are well-known in theart. For example, tiles can be formed in molds, extruded, or stampconstructed. The sheathing surfaces 12 of the subject invention can bemanufactured, utilizing standard techniques, to required thicknesses,which will be determined by their ultimate construction application. Forexample, when utilized as wall or siding cover, it may be possible toconstruct the sheathing surface 12 of a relatively thin layer oflightweight concrete. However, for other applications, for exampleroofing construction, a thicker layer of lightweight concrete could beutilized. When utilized as roofing tile panels, the sheathing surface12, in a preferred embodiment, is approximately ⅛″ to about ½″ inthickness. In a more preferred embodiment, the thickness is from about¼″ to about ⅜″. In a most preferred embodiment, the sheathing surface 12is about 5/16″ in thickness. In addition to other desirablecharacteristics, known to those with skill in the art, lightweightconcrete provides sufficient durability to allow walking, kneeling, etc.on the tiles during installation. The concrete is also resistant to windand water. If desirable, the concrete can also be tinted or coloredbefore, during, or after the manufacture of the tile panels of thesubject invention using well-known techniques and products. Utilizinglightweight concrete for the sheathing surface 12 allows the tile panels10 to be used on standard roofing or decking assemblies 16, usuallywithout the need for reinforcements, which are sometimes necessary withstandard clay or concrete tile roofs. It is also possible to utilizeexisting manufacturing techniques, molds, etc. that would be used withstandard clay or concrete tile manufacture. Therefore, the tile panelsof the subject invention can save costs on manufacturing, constructionmaterials, and time. A further advantage of lightweight concrete is thatit can be molded and shaped to provide almost any desired configuration,for example as shown in FIG. 1. In a preferred embodiment, the tilepanels of the subject invention are colored and shaped to look likestandard clay tiles. However, it should be understood that any shape orconfiguration could be utilized, including variations on the standardclay tile design. For example, in an alternative embodiment, the tilepanels of the subject invention are a flat or shingle-type style. In afurther alternative embodiment, the shingle tiles of the subjectinvention are manufactured and colored to mimic standard shingles, slateor other flat or contoured tile designs.

In most tile roofing construction, tiles are laid in an overlappingfashion and it is usually the weight of the tiles and the frictionbetween the rough tile surfaces that hold the tiles in place. In somesituations, the tiles may be secured to the roof decking, or underlyingsupport structure. This can be accomplished by a variety of meansincluding the use of grout or an adhesive, or nailing or screwing thetiles to the roof decking. In a preferred embodiment of the subjectinvention, each tile panel 10 is secured to the roof decking. Thisprovides resistance to wind-lifting or other forces that couldreposition the tiles. Therefore, in a further preferred embodiment, oneor more openings or mounting holes 14 are created in the tiles, bytechniques known to those with skill in the art, to accommodate theirattachment to a roof decking. For example, the holes may be formed inthe sheathing surface 12, and/or the backing material during manufactureof a tile panel 10, or alternatively could be created in the tile panelafter manufacture. In a further preferred embodiment, the openings ormounting holes 14 can be formed at angles, such that the nails or screwsare inserted at angles relative to the roof decking 16, rather thanperpendicular to the roof decking. In a still further preferredembodiment, the openings or mounting holes 14 are at approximately 40°to about 75°, relative to the roof decking or other support surface.This technique can increase the holding strength of nails or screws.Another consideration is the number of mounting holes created in thetiles, which will vary depending upon the type of tile. It is preferablefor the tiles to have a sufficient number of mounting holes 14 so as toprovide adequate resistance to wind lifting. The mounting holes 14extend through the sheathing surface 12 and the associated backingmaterial 20, which will be discussed below. The mounting holes 14 can bein any location on the tile panel. However, for certain tile shapes, forexample, barrel-style tiles it is preferable for the mounting holes 14to be located where there is a minimum distance between the sheathingsurface and the support structure, e.g., roof decking. For example, asillustrated in FIGS. 1 and 5, if utilizing barrel-style tiles, it may bepreferable to have mounting holes 14 in the downward-curved areas,preferably at the bottom of a curve, closest to the roof decking.Further, as illustrated in FIG. 6, it is preferred that mounting holes14 be located in an area of the tile that is proximal to its trailingedge so that the mounting hole is covered by the overlap of another tilewhen in its final assembled configuration, so that exposure of thefastener to the elements is minimized.

In a further preferred embodiment, the tiles can be connected to theroof decking utilizing standard screws or nails and equipment known tothose with skill in art. In addition, an adhesive, grout, sealing, orsimilar material can be used in addition to nailing or screwing thetiles to the roof decking. This can assist in maintaining the properpositions of the tile panels, and in regions of more prevalent strongwind conditions, provide desirable additional resistance towind-lifting. In a preferred embodiment, an adhesive, such as thoseknown in the art, is applied either to the backing material of the tilepanels, the surface of the support structure, or both of them, prior toinstallation to adhere the tile panels to the roof decking or othersupport structure.

The tiles of the subject invention can be manufactured to a variety oflengths and widths. Tile panels 10 that cover a larger surface area canbe easier to install and reduce labor costs. In one embodiment, the tilepanels 10 of the subject invention could be manufactured to a standardsize of approximately 12- in length (from the leading edge 150 to thetrailing edge 300) and approximately 18″ in width (side-to-side).However, in a preferred embodiment, the tile panels 10 of the subjectinvention can each cover approximately 3 to 4 feet of surface area.However, a person with skill in the art will recognize that the lengthand width of the tiles would be based upon the desired roof style anddesign. Utilizing moldable lightweight concrete makes it possible tocreate numerous tile designs, including for example, Roman, Greek,Italian, English, Spanish, etc. designs, or entirely unique tiledesigns, without significantly altering the methods of the subjectinvention. Further, the ultimate shape and size of the tiles utilizedwith any design will be dependent upon the given structure to which thetiles are to be installed.

As mentioned above, wind-lifting of tiles on a roof is a significantfactor to consider in many areas of the world. In order to combat thiseffect, it is desirable to reduce or minimize the amount of air spaceunder the tile panels. The subject invention utilizes a material on thebottom side 24 of the sheathing surface 12 to reduce the amount of airspace under the tiles. By reducing the amount of air space that ispresent under tile panels 10 when assembled according to the teachingsherein, the tile panel 10 is less susceptible to lifting by wind.Numerous materials and techniques useful for filling or reducing the airspace on the bottom side 24 of the tile panels 10 of the subjectinvention will be apparent to one with skill in the art. For example,backing materials can be selected from various materials, includingplastics, woods, metals, lightweight concretes, ceramics, clays, foams,or combinations or composites thereof.

In one embodiment, the tile panels are constructed of materials capableof rendering a “cellular solid” product. In this embodiment, the tilecan be created with any of a variety of decorative outer surface shapes,and styles, but could have a bottom surface 24 that conforms to theshape of the support surface to which it will be attached. For example,a barrel-style tile panel to be utilized on a roof decking could have arolling or curved top surface 26 and the bottom surface 24 could besubstantially flat so as to lay or be adhered flush against the roofdecking.

In other embodiments, a backing material 20 can be utilized with thesubject invention. In a preferred embodiment, the backing material 20utilized with the subject invention should be water resistant and easilyformable to accommodate a variety of shapes of tile panel 10. It shouldalso be of sufficient rigidity to maintain its shape during manufactureand installation of the tile panels and during high wind conditions.Further, a high insulation capability, or R value, is desirable.Depending upon the type or style of backing material utilized, it can beapplied, affixed or connected to the sheathing surface by a variety oftechniques known in the art. By way of example, certain types of backingmaterials 20 can be pre-formed to the required shape of the sheathingsurface to which it will be adhered, or alternative means to conform theshape of the backing material 20 to the required shape of the sheathingsurface 12 may be utilized.

In a further example, backing materials 20 may be applied to the insidesurface of the sheathing surface 12 by various spray techniques known tothose with skill in the art, or, as another example, layers of backingmaterial could be stacked and formed to fill the space under thesheathing surface 12. In a further example, the backing material can beformed in molds compatible with the shape of the bottom side 24 of thesheathing surface 12. In various alternative embodiments, the backingmaterial may be extended beyond the edges of the sheathing surface. Invarious alternative embodiments, the backing material may be extendedbeyond one or more edges of the sheathing surface. In generallypreferred embodiments, the backing material does not extend beyond, andmay be offset from, one or more edges of the sheathing surface.

In an alternative embodiment, the sheathing surface 12 can bemanufactured to have a relatively flat bottom side 24, regardless of thedesign, contours or shape of the top side 26 of the sheathing surface.Thus, it would not be necessary to mold or form backing material 20 tothe shape of the potentially variable top side 26. In this embodiment,backing material can be attached to the bottom side 24 of the sheathingsurface 12 using a variety of techniques, without the need to shape ormold the foam to conform to a particular shape of the sheathing layer.The bottom of the sheathing layer 12 can be flat and flat panels ofbacking material 20 could readily be fixedly attached thereto.

In still further alternative embodiments, the sheathing layer 12comprises a composite material. Such a composite material couldcomprise, for example, foam particulate matter or a foam coreencapsulated in concrete, clay, or other material. In such anembodiment, the sheathing surface 12 could be prepared, as describedabove, with any variety of top side 26 configurations and a bottomsurface 24 that conforms to the shape of the support surface to which itwill be attached. In further alternative embodiments, additional backingmaterial 20 could be affixed to the bottom surface 24 of the compositematerial to provide additional insulation and/or resistance to windlifting by thoroughly filling all available air space under thesheathing surface 12.

In preferred embodiments, substantially rigid, closed-cell foam isutilized as a backing material 20 with the tile panels 10 of the subjectinvention, for example, not limited to, polystyrene and/or polyurethanefoam. Substantially rigid, closed-cell foam backing material 20 canresist water absorption and/or retention and provide additional strengthto the tile panels of the subject invention. Further, it can provide ahigh insulation capacity and can be made to conform to any shape orstyle of sheathing surface, flat or otherwise. In more preferredembodiments, polystyrene and/or polyurethane foam is used in conjunctionwith the sheathing surface 12.

In further preferred embodiments, the tile panels 10 are of a laminateconstruction, wherein foam backing material 20 is pre-formed to matchthe shape of the underside 24 of the sheathing surface to which it is tobe adhered, for example, as shown in FIGS. 1-5 and in FIGS. 6A and 6B.In other embodiments, the backing material can be offset from one ormore edges of the sheathing material. In alternative embodiments, thebacking material can extend to one or more edges of the sheathingsurface or, in a still further alternative embodiment, the backingmaterial can extend over and/or beyond one or more edges of thesheathing surface.

The rigid closed-cell foam backing material 20 can be fixedly attachedto the sheathing surface in a variety of ways, including using adhesivesor tapes, screws, nuts, bolts, nails, etc. It can also be integratedinto the sheathing surface, for example by providing a means for thelightweight concrete of the sheathing surface 12 to incorporate into asurface of the foam backing material 20, such as, for example, duringthe manufacturing process.

In one embodiment, concrete or other suitable tile material can bepoured, sprayed, or otherwise distributed into a tile mold and vibratedto evacuate any air pockets or bubbles in the material. A pre-moldedfoam surface 22 can then be pressed into, or otherwise brought intocontact with the concrete on the eventual bottom side 24 of thesheathing surface before the concrete “sets” into the preferred tilepanel shape. In this embodiment, it is important that the surface of thefoam that is to be laminated with the concrete be relatively clean andfree of debris so as to ensure good adherence with the concrete or othermaterial. In another embodiment, the molded surface 22 of the foambacking material 20 is prepared prior to being pressed into the concreteto provide a corrugated or roughened surface, grooves or other types ofdepressions for the concrete to enmesh with or adhere to, in order tohold the foam securely against the bottom side 24 of the sheathingsurface.

In a preferred embodiment, an expanding foam liquid material is utilizedwith the tile panels of the subject invention. In this embodiment, anyof a variety of foams in a liquid or semi-liquid form, known to thosewith skill in the art, can be poured, sprayed, or otherwise distributedonto at least a portion of the back of a tile sheathing surface. In apreferred embodiment, almost the entire back surface of a tile sheathingsurface is covered with expanding foam. In a further preferredembodiment, the subject invention is utilized with a liquid foammaterial that forms a closed-cell, rigid, or semi-rigid foam backingmaterial. For example, urethane or polyurethane foam liquid arewell-known in the art and could be used with the subject invention.However, a person with skill in the art would be able to determine oneor more foam materials that would be suitable for use in the particularenvironment and/or the intended use of the tile panels of the subjectinvention. For example, in certain applications, it may be preferable toutilize open-cell foam.

As mentioned previously, it is desirable to reduce or eliminate theamount of air space under and around the tile panels. For the backingmaterial 20 to effectively reduce the air space, it should fill as muchavailable space as is practical between the roof decking 16, or othersupport structure, and the underside 24 of the sheathing surface.Therefore, the surface of the bottom side of the backing material 28 canideally conform to the shape of the roof decking or other support towhich it will be adhered. For example, the surface of the bottom side of28 of a backing material 20 can be flat so as to lie against a standardplywood roof decking 16. In the preferred embodiment, tile panels 10with cross-sections of various heights, such as for example, barrel- orSpanish-style tiles, will have the thickness of the backing materialvary across different sections of the tile. An example of thisembodiment is shown in FIGS. 1-5, wherein FIG. 1 is an example of a tilepanel utilizing a curvilinear sheathing surface 12 and FIGS. 4 and 5illustrate how the thickness of the backing material 20, such as, forexample, foam, will vary at different length-wise cross-sections of thetile panel 10.

As mentioned above, in a preferred embodiment, the tile panels of thesubject invention can be manufactured with any of a variety of foambacking materials. As mentioned above, one side of the foam backingmaterial can be pre-formed to conform to the shape of the tile sheathingsurface. In this embodiment, the side of the backing material that willbe in contact with the roof decking 16 can also be manufactured inshapes that will conform to the surface shape(s) of the roof decking. Ina preferred embodiment discussed above, the backing material cancomprise a liquid expanding foam. In this embodiment, the fully expandedand sufficiently cured foam can be cut by techniques known in the art toany shape necessary to conform to a roof decking.

For certain applications of the tile panels of the subject invention,such as a roof covering, it may be necessary to adjust the angle atwhich the tile panels overlap. This can ensure that the tile panels moreaccurately or closely follow the angle or pitch of a roof. In standardroofing tiles, it is well known in the art to taper or slant thetrailing edge 150 of a tile so that overlying tiles do not adopt astep-wise progression up the slope of the roof, which can prevent thetiles from laying flush with the roof decking or other underlyingsupport, particularly at or near the lower roof line or ridge line. Inthe subject invention, the backing material 20 can be molded, cut orotherwise formed to achieve an angle sufficient to ensure flush mountingof the installed tiles on a roof. For example, FIGS. 4 and 5 illustrateflat tile panels wherein the backing material is formed at an angle suchthat the thickness of the foam material at the trailing edge 300 of thetile panel is less than that at the leading edge. This allows thetrailing edges of tile panels to be overlapped by the leading edges oftile panels and still maintain generally complete contact with a roofdecking.

As mentioned above, the tile panels may be secured to an underlyingsupport using nails, screws, etc., optionally along with an adhesive,grout, or similar material. By maximizing the contact area between thebacking material 20 and the underlying support, it allows for a greatersurface area between the backing material 20 of the tile panel and theunderlying support structure to be held together using an adhesive,grout, or other material. The thickness of the foam can vary dependingupon the type or style of sheathing surface utilized, the environmentalconditions, available installation space, or type of foam utilized, etc.A person with skill in the art will be able to determine an appropriatefoam thickness to achieve adequate insulation properties and/or tilesupport. In order for the tile panels 10 to overlap, as usually desiredfor tile installations, it is necessary to ensure that the backingmaterial 20, such as, for example, foam, or other material (composite,cellular solid, etc.) under the sheathing surface is contoured or formedto provide sufficient clearance to accommodate the surrounding tiles. Incertain embodiments, the backing material 20 of foam or other materialextends only partially to the edges of the tile panels 10. This providesan insertion gap 30 around the tile panels 10 to accommodate thesurrounding tile panels 10. In a preferred embodiment, the backingmaterial 20 is extended to the edge of the tile panels 10 a sufficientdistance so that, when installed, it will buttress against the backingmaterial 20, for example, foam, or other material, in the surroundingtile panels to create a substantially contiguous, preferably foam, layeracross a roof or other structure under the sheathing surface 12. Thisallows for the interlocking of the tiles during installation, whichfurther increases their resistance to wind-lifting. One example of thisembodiment is shown in the barrel-style tile panels in FIGS. 2A and 3A,wherein the overlapping side edge 32 of the first sheathing surface 12,shown in FIG. 3, is angled to fit over and against the underlying sideedge 34 of a second sheathing surface 12 so that the backing material 20underneath both sheathing surfaces 12 is adjacent to form an essentiallycontiguous layer. A further example of the overlapping side edges 32 and34 are shown in FIGS. 2B and 3B, wherein flat-style panels are shownwith an overlapping side edge 32 and an underlying side edge 34 shown ona tile panel.

For certain styles of tile panels 10, it is possible to further includeone or more interlock channels 36, for example, as shown in FIGS. 4, 5,6A and 6B. One or more interlock channels 36 can allow the tile panels10 to be firmly seated against each other to provide further stabilityafter installation. The one or more interlock channels 36 can furtherreduce the ability of tile panels 10 to be lifted, twisted or otherwisedisplaced. In this embodiment, the edge of the sheathing surface 12 ofan upper located tile panel 10 is positioned above a lower second tilepanel 10, which has been mounted on the support structure, and theinterlock channel 36 of the upper tile panel engages the edge of thesheathing surface 12 of the lower mounted second tile panel. Asmentioned above, the offset, preferably foam, backing material 20 oneach tile panel when installed will be adjacent to form an essentiallycontiguous layer under the sheathing surfaces 12. An example of thisembodiment is shown in FIGS. 6A and 6B. In a preferred embodiment, atile panel 10 comprises at least one interlock channel 36 at the leadingedge 150 to accommodate the trailing edge of at least one other tilepanel 10. In this embodiment, an interlock channel is formed under oneor more sheathing surfaces wherein the bottom side of the sheathingsurface defines some portion of the interlock channel, such that the topside of the trailing edge 300 of one sheathing surface is in contactwith the bottom side of the leading edge 150 of a second sheathingsurface.

In alternative embodiments, the leading edge 150 of a sheathing layercan be modified to include one or more interlock channels. In suchembodiments, the trailing edge 300 of a first sheathing surface of onetile panel can be positioned within the interlock channel 36 in theleading edge 150 of the sheathing surface of an adjacent tile panel. Toaccommodate an interlock channel 36, the sheathing surface 12 cancomprise an overall greater thickness, or it can be formed thicker atone or more edges so that an interlock channel 36 can be formed therein.

In a still further alternative embodiment, one or more interlockchannels 36 can be formed entirely within the backing material 20. Forexample, the backing material 20 can be sufficiently extended to theleading edge 150 of a first tile panel 10 sheathing surface 12 so thatan interlock channel can be formed therein that will accommodate thetrailing edge 300 of a second tile panel 10 sheathing surface 12. Inthis embodiment, the edge of the sheathing surface 12 of the second tilepanel that is engaged with the interlock channel 36 of the first tilepanel will be in contact only with the backing material. Thus, the edgesof the sheathing surfaces 12 will be substantially covered with backingmaterial and will not be in contact.

In a yet further alternative embodiment, the backing material of thesecond tile panel can be extended past the edge, or may even cover orpartially surround, the trailing edge 300 of the sheathing surface, forexample as shown in FIG. 14. In this embodiment, when the leading edge150 and the trailing edge 300 are engaged, the backing material 20 ofthe interlock channel 36 of the first tile contacts the backing material20 surrounding, or partially surrounding, the trailing edge 300 of thesecond tile panel. This can provide an even more airtight seal toprevent windlift.

In most roofing designs, there are one or more roof apex points or dripedges that must be covered in addition to the other areas of the roofstructure. In tile roofs, these areas usually require special tiles to“cap” or seal the exposed edge. Following are examples of a specializedridge crown panel 40, hip panel 50, gable panel 60, drip edge panel 70,and a valley seal 80 that can be utilized with the installation methodand tile panels 10 of the subject invention.

EXAMPLE 1 Roof Drip Edge Panel

In most conventional roof structures, particularly tile roof structures,the drip edge of the roof is a weak point which allows the ingress ofthe elements, particularly wind. It is wind ingress on the leading edgeof a roof line that can be particularly severe. In high wind conditions,the edge can be lifted from the support structure exposing theunderlying roof decking to the elements, or, in extreme circumstances,completely removing the tiles. Therefore, it is desirable to close orseal the drip edge to resist wind-lift.

Referring to FIGS. 9 and 10, the subject invention provides for a dripedge panel 40 that can secure and protect the leading drip edge tilepanels 10. The drip edge panel 40 can comprise a variety of materials,which will become apparent to one with skill in the art. However, in apreferred embodiment, the drip edge panel 40 comprises a lightweightconcrete, as described for the sheathing surface. In one embodiment, adrip edge panel 40 is an elongated panel comprising a leading edge guard44 and one or more mounting holes 14.

A drip edge panel can comprise a variety of decorative or functionalshapes, or surface configurations. In addition, a person with skill inthe art will readily recognize numerous shapes for drip edge panels orcomponents thereof that would be appropriate for use with the subjectinvention. Such modifications are contemplated to be within the scope ofthe present invention.

A drip edge panel 40 is designed to be inserted and secured under thetile panels 10 at the edge of a roof, particularly on a roof drip edge.Once installed, the leading edge guard 44 on the drip edge panel 40provides a “wind-break” on the front side of the leading edge of tilepanels 40, which can reduce or eliminate wind-lifting of the leadingedge tile panels. Therefore, in a preferred embodiment, the frontprofile 48 of the leading edge guard 44 is compatible with the profileof the tile panel 10 against which it will be used. For example, ifutilized with barrel-style tile panels, the front profile 48 may becurvilinear to match the profile of the barrel-style tile panels. FIG.10 illustrates an example of this type of drip edge panel 40.

In a further preferred embodiment, the drip edge panel 40 comprises atleast one interlock flange 42 on the backside 45 of the edge panel thatcan be inserted into an interlock channel 36, discussed above, in a tilepanel 10. An interlock flange 42, for example as shown in FIG. 9, canprovide further stability to and proper installation of a drip edgepanel 40, as well as helping to secure the interlocked tile panel 10against wind lifting. The interlock flange can be contiguous or compriseone or more sections.

In a still further preferred embodiment, a drip edge panel 40 cancomprise a drip edge 46 along the front of the leading edge guard 44.The drip edge 46 can be straight, bent or curved to any desired angleand may have a variety of designs or decorations incorporated into orthereon. The drip edge 46 can provide a controlled flow of water fromthe tile panels 10 away from the roof fascia and sides of a home orbuilding.

The drip edge panels can be secured using a variety of techniques andmethods. They can be secured to the edge of the roof structure and/orthe tile panels 10 at the roof edge.

However, in a preferred embodiment, the drip edge panels 40 furthercomprise mounting holes 14. Once positioned, the drip edge panels can besecured using standard roofing nails or screws in the mounting holes 14.The proximity of the nails and/or screws along the edge of a roof andthe use of an interlock flange 42 in an interlock channel 36 lends thetile panel 10 system of the subject invention even further resistance towind-lifting.

EXAMPLE 2 Ridge Crown Tile Panel

Standard roof designs usually have at least one roof ridge which must besealed, particularly on tile roof designs, to protect underlying roofstructure or roof decking from the elements. This can be accomplishedwith a variety of techniques and devices known to those with skill inthe art. Usually overlapping concave curved or rounded tiles areinstalled along the roof ridge to prevent ingress of water and otherelements under the tiles. Often, a beam of 2″×4″ or 2″×6″ board ispositioned along the ridge line to which the curved or rounded tiles maybe secured with one or more nails or screws and, often, an adhesivematerial. However, these techniques, with or without the additionalboard, create large areas of air space under the tiles making themsusceptible negative pressure effects and wind-lift.

To address this problem, the subject invention utilizes a crown tilepanel 50. A crown tile panel can comprise a variety of decorative orfunctional shapes, or surface configurations. A person with skill in theart will readily recognize numerous shapes for crown tile panels thatwould be appropriate for use with the subject invention. Suchmodifications are contemplated to be within the scope of the presentinvention.

A preferred embodiment of the crown tile panel 50 of the subjectinvention comprises an elongated curved sheathing surface 52, similar tothat described above, having a concave bottom side 24 or curved profilethat can be installed in an overlapping fashion across a roof ridge. Anexample of this embodiment is shown in FIGS. 7A and 7B. In a furtherembodiment, the sheathing surface 12 of the crown panel 10 comprises aninterlock method to assist in maintaining the position of the installedtiles along the roof ridge. In this embodiment, the top surface 26 orconvexly curved profile trailing edge 300 of the crown panel 50comprises a notch or groove 54 around the convex circumference of thesheathing surface. The leading edge 150 of the tile comprises a collar56 extending around at least a portion of the concave bottom side of thecrown panel 50, and follows the circumference of the curved tile panel50, for example, as shown in FIG. 7B. When laid end to end, the collar56 on a first crown panel can be positioned in the groove 54 of a secondcrown panel in an essentially straight line along a roof ridge, of whichan embodiment of this assembly is shown in FIG. 7D.

The crown panels 50 of the subject invention can be secured to the roofridge similarly to the other tiles described above, in that they can beadhered to the tile panels 10 with adhesives, grouts or similarmaterials. Alternatively, a 2″×4″ or 2″×6″ board can be positioned alongthe roof ridge, between the tile panels 10 and the crown panels 50secured thereto with standard nails or screws, optionally in addition tousing an adhesive or similar material.

In an alterative embodiment, a locking track 58 is incorporated with thecrown panels 50 to facilitate better adherence to a roof ridge beam 100,such as a 2″×4″ or 2″×6″ board or other similar device. In a preferredembodiment, the locking track 58 is a substantially U-shaped frame ofapproximately the same length as a crown panel 50, as illustrated inFIGS. 7A, 7B and 7C. In further preferred embodiments, the locking track58 is designed to fit over a roof ridge beam with minimal amount ofspace between the locking track 58 and the beam. As will be discussedbelow, the locking track 58 can, further, be fixedly attached to a beamvia an adhesive applied to the inside of the locking track 58, the beam,or both. The dimensions of the locking track 58 utilized with thesubject invention can vary. Such variances can be adjusted according tothe size, shape and length of the beam, manufacturing and/orinstallation considerations, construction materials, etc. Crown panelscurrently known in the art usually sit on a roof ridge beam, such thatthe only contact between them is where the underside of the crown paneltouches the top edge of the roof ridge beam. However, in a preferredembodiment of the crown panel of the subject invention, the dimensionsof the locking track 58, which actually straddles at least a portion ofthe beam and extends along at least a portion of the sides of the beam,are such that there is approximately 25% to about 200% additionalsurface area or more that can be utilized to contact, hold and/or adherethe crown panel 50 to a beam. In a further preferred embodiment, thedimensions of the locking track 58 are such that there is at least about200% more surface area that can be utilized to contact, hold, and/oradhere to the crown panel 50 to a beam.

The locking track 58 of the subject invention should comprise materialsuitable for contact with and, preferably, adherence to, a roof beam,for example, various types of plastics, woods, metals, concretes, foams,or combinations or composites thereof, may be utilized. In a preferredembodiment, the locking track 58 comprises a rigid material ofsufficient durability and strength to hold a crown panel 50 in placealong the roof ridge and withstand environmental conditions for severalyears. It can be molded into the sheathing surface, or defined in thebacking material, or incorporated in addition to the backing materialand the sheathing surface.

In a further preferred embodiment, foam or foam-like backing material 20is utilized with the crown panels on both sides of the locking track tofurther reduce the amount of air space under the crown panels 50, andprovide additional benefits as described above. The foam backingmaterial 20 utilized with the crown panel 50 should be configured so asto accommodate the surrounding roofing tile panels 10 against which itwill be set. Therefore, it may be necessary for the foam backingmaterial 20 to be molded or fixedly attached in an accommodating fashionso that the crown panels 50 can be positioned against the roof tilepanels 10 so as to reduce the ingress of elements, particularly wind,under the crown panels 50. FIG. 7A depicts a cross-section of a crownpanel wherein the foam backing material 20 is molded towards the apex ofthe curve to accommodate the surrounding roof tile panels against whichit would be placed in operation.

In a further preferred embodiment, the locking track 58 is fixedlyconnected to the crown panel 50. This can be accomplished by severalmeans known in the art, including, but not limited to adhesives, screws,nuts, bolts or other attachment means. In a preferred embodiment, thelocking track 58 further comprises an anchor end 59 that is pressed,pushed, or otherwise set into the lightweight concrete during themanufacture of the sheathing surface 52. In a further preferredembodiment, the anchor end 59 comprises ridges, grooves, holes, or othermeans whereby the concrete can integrate with the anchor end 59 so that,when the lightweight concrete is firm, the locking track 58 is securelyaffixed to the bottom side 24 of the sheathing surface.

During installation the crown panel is positioned over the roof beamwith the locking track 58. Mounting holes 14 in the crown panel can beused to secure it to the beam. Additionally, an adhesive, grout,additional cement, or similar materials can be used to further securethe locking track 58 to the beam. Additional crown panels are positionedend to end via the tongue 56 and groove 54 mechanisms described above.

In still further preferred embodiments, portions of the backing material20 or locking track 58, or both of these, can extend slightly forward attheir leading edge 150 so as to be received under the trailing edge 300of an adjacent crown panel during installation, thereby providing stillfurther increased resistance to wind lifting.

It is well known in the art to use caps on the ends of the roof ridgetiles to close and/or seal the exposed tile ends. In an embodiment ofthe subject invention, crown panel caps may also be utilized to close,seal or otherwise cover the ends of the curved tile panels at the endsof the roof ridges. In a preferred embodiment, the caps utilized withthe subject invention will also utilize a locking track 58.

EXAMPLE 3 Hip Tile Panel

The hip of a roof is a point where a roof makes a turn to go in anotherdirection. Usually, hip lines extend downward from an essentiallyhorizontal roof ridge. This presents another area that should be sealedagainst the elements, particularly wind and water. To cover and protectthese areas when using the tile panel of the subject invention to covera structure, the subject invention utilizes an elongated hip panel 60. Ahip panel 60 of the subject invention combines features of the crownpanel and the tile panel to provide a secure, wind and weather resistantcovering for a roof hip. An example of one embodiment of a hip panel 60of the subject invention is shown in FIGS. 8A and 8B. In a preferredembodiment, the hip panels 60 overlap in an end-to-end fashion along theline of a roof hip.

A hip tile panel can comprise a variety of decorative or functionalshapes, or surface configurations. In addition, a person with skill inthe art will readily recognize numerous shapes for hip tile panels thatwould be appropriate for use with the subject invention. Suchmodifications are contemplated to be within the scope of the presentinvention.

One embodiment of a hip panel comprises a sheathing surface 62 with acurved profile, similar to that used for crown panels 50. In thisembodiment, the concavely curved surface defines the bottom side 24 ofthe sheathing surface and the convexly curved surface defines the topside 25 of the sheathing surface. However, the sheathing surface 62 mayresemble any shape or configuration, and can include other decorative orfunctional features as necessary or desired. It is most important thatthe sheathing surface 62 provide sufficient protection and drainagecharacteristics to protect the underlying roof support structures.

In a further embodiment of a hip panel, a locking track 64 is integrallyconnected to the bottom side 24 of the sheathing surface 62, similarlyas discussed previously for a crown panel 50. The locking track 64 ofthe hip panel 60 is of sufficient length to ensure proper and secureplacement of the hip panel, but does not interfere with the insertion ofadditional hip panels above or below it. An example of a locking track64 used with a hip panel of the subject invention is shown in FIG. 8B.Thus, when installing a hip panel 60, a beam, for example, but notlimited to, a 2″×4″ or 2″×6″ board, is installed along the length of theroof hip line, between the tile panels 10 on either side of the roof hipline. The beam can be held in place by a variety of techniques andmethods that will be apparent to one with skill in the art. However, ina preferred embodiment, the beam utilized with the hip panel 60 of thesubject invention is secured to the roof structure with straps ofsufficient strength to withstand extreme weather or high windconditions. In a further preferred embodiment, hip panels 60 arepositioned along the length of the beam using the locking track 64 toensure proper and secure placement.

In a still further embodiment, hip panels 60 can be held in place alongthe length of the beam utilizing devices or methods known in the art. Ina preferred embodiment, the hip panels 60 further comprise mountingholes 14, as discussed above, through which standard roofing nails orscrews can be used to secure the hip panels 60 to the beam. In a furtherpreferred embodiment, an adhesive, grout, or similar material is alsoutilized between the beam and the locking track 64 to further secure thehip panels 60 to the beam.

In a still further embodiment, the hip panels 60 comprise foam backingmaterial 20 on the bottom side 24 of the sheathing layer 62, on bothsides of the locking track, as described above for the crown panels 50.As discussed above, the foam backing material 20 fills the air spaceunder the hip panels 60 to combat negative pressure effects and providea further insulation factor.

In an alternative embodiment, the foam backing material can be formedwith locking channel 64 therethrough such that a separate lockingchannel would not be necessary. In this embodiment, the foam-formedlocking channel 64 is seated and affixed directly onto the beam.

In a preferred embodiment, the foam backing material 20 is molded,formed or otherwise positioned so as not to interfere with the placementof a hip panel 60 against the tile panels 10 on either side of the roofhip line, for example as shown in FIG. 8A. In a further preferredembodiment, the foam backing material 20 provides an additional meansfor interlocking the hip panels 60 during installation. In thispreferred embodiment, the foam backing material 20 of the hip panels 60further comprises one or more interlock channels 66 at the leading edge200 of the hip panel 60 for example, as shown in FIGS. 8A and 8B. Inaddition, the trailing edge 400 of the hip panel provides an overlap 68in the sheathing layer 62 that corresponds to the shape of the interlockchannel 66.

During installation, the hip panels 60 are placed in an ascendingover-lapping fashion, wherein the overlap 68 at the trailing edge 400 ofa first installed, usually lower, hip panel is inserted under thesheathing surface 62 of a second installed, usually higher, hip panel sothat the overlap 68 of said first hip panel inserts into the at leastone interlock channel 66 in the foam backing material 20 at the leadingedge 200 of the second overlapping hip panel 60.

In a further preferred embodiment, the foam backing material 20 of onehip panel 60 is configured complementary to the foam backing material 20of the adjacent hip panels forming an essentially continuous layer offoam backing material 20 under the installed hip panels 60. This canhelp combat negative pressure effects and provide an additionalinsulation factor.

It is also well known in the art to use caps on the ends of the roof hiptiles. In an embodiment of the subject invention, hip panel caps mayalso be utilized to close, seal or otherwise cover the ends of the hippanels 60 at bottom of roof hip line. In a preferred embodiment, thecaps utilized with the subject invention will also have a locking track68, and the overlapping and interlocking capabilities described for thehip panels to allow proper drainage.

EXAMPLE 4 Gable Panel

A roof with a gabled end is one with a straight slope falling from theroof ridge to the eave creating a peak on the side or front facade.Gabled roofs have rakes on the gabled facades that should be protectedto prevent access of rain and wind under the roofing tiles to theunderlying roof support structures.

The subject invention utilizes a gable end panel 70 to cover and protectthis area of a roof. In one embodiment, the gable end panel 70 comprisesseveral features of the above-described tile 10, crown 50, and hip 60panels. One embodiment of a gable end panel 70 of the subject inventionis shown in FIG. 11.

A gable end panel can comprise a variety of decorative or functionalshapes, or surface configurations. In addition, a person with skill inthe art will readily recognize numerous shapes for gable end panels thatwould be appropriate for use with the subject invention. Suchmodifications are contemplated to be within the scope of the presentinvention.

In a preferred embodiment, the gable end panels 70 of the subjectinvention comprise a curved sheathing surface 72, a leading edge 200 anda trailing edge 400, an outside edge 78 of the sheathing layer 72 thatextends over the roof rake and an inside edge 79 that extends over theroof or other structure. In another preferred embodiment, the outsideedge 78 of the sheathing surface is elongated to cover a greater area ofthe fascia board or beam, discussed below. This can provide a morecontrolled drainage of water from the roof. However, it should beunderstood that the gable end panels 70 of the subject invention mayresemble any shape or configuration, and can include other decorative orfunctional features as necessary. It is most important that the shape ofthe gable end panel provide adequate drainage and protection for theunderlying roof support from the environmental elements, particularlyrain and wind. It will be apparent to one with skill in the art thatnumerous functional or decorative shapes may be utilized for thesheathing surface 72.

In a further embodiment of a gable end panel 70, a locking track 74 isintegrally connected to the bottom side 24 of the sheathing surface 72,similarly as discussed previously for a crown 50 or hip 60 panel. Thelocking track 74 of the gable end panel 70 should be of sufficientlength to ensure proper and secure placement of the gable end panel, butshould not interfere with the insertion of additional tile panels aboveor below it. An example of a locking track 74 used with a tile panel ofthe subject invention is shown in FIG. 11. To install a gable end panel70, a beam or fascia board, for example, but not limited to, a 2″×4″ or2″×6″ board, is fixedly connected along the length of the roof rake lineusing techniques known in the art. In a preferred embodiment, gable endpanels 70 are positioned along the length of the beam using the lockingtrack 74 to ensure proper and secure placement. An embodiment of thelocking track 74 that can be utilized with the gable end panels 70 isshown in FIG. 11.

In a preferred method of installation, the gable end panels 70 areinstalled in an ascending end-overlapping-end fashion using the lockingtracks 74 to ensure proper and secure placement. In a further preferredembodiment, the gable end panels 70 comprise mounting holes 14 forsecuring the gable end panels 70 to a beam. In a still further preferredembodiment, an adhesive, grout or similar material is used between thelocking track 74 and the beam to further secure the gable end panels 70.

In a further embodiment, the gable end panels 70 comprise foam backingmaterial 20 on the bottom side 24 of the sheathing layer 72, on bothsides of the locking track, as described above for the crown 50 and hip60 panels. As discussed above, foam backing material 20 can fill airspace under the gable end panels 70 to combat negative pressure effectsand provide a further insulation factor. In a preferred embodiment, thefoam backing material 20 can be molded, formed or otherwise positionedso as not to interfere with the placement of gable end panels 70 againstthe tile panels 10 on edge of gable roof end line, for example as shownin FIG. 11.

In a further embodiment, the foam backing material 20 provides anadditional means for interlocking the gable end panels 70 duringinstallation. In a preferred embodiment, the foam backing material 20 ofthe gable end panels 70 further comprises one or more interlock channels76 at the leading edge 200 of the gable end panel 70 for example, asshown in FIG. 11. In addition, as described above for the hip panels 60,the trailing edge 400 of the gable end panel 70 provides an overlap inthe sheathing layer 72 that corresponds to the shape of the interlockchannel 76.

During installation, the gable end panels 70 are positioned similarly asdescribed above for the hip panels 60. The gable end panels 70 areinstalled in an ascending fashion, wherein the sheathing layer overlapin the distal end 400 of a first installed gable end panel slides underthe proximal end 200 of the sheathing layer of a second installed gableend panel, and interlocks with the interlock channel 76 in the foambacking material 20 of the second gable end panel. In a furtherpreferred embodiment, the foam backing material 20 of one gable endpanel 70 is configured to abut against the foam backing material 20 ofthe adjacent gable end panels forming a substantially continuous layerof foam backing material 20 under the installed gable end panels 70.This can combat negative pressure effects and provide an additionalinsulation factor.

EXAMPLE 5 Roof Valley Seal

The valley on a roof is created when a roof changes direction. It is thepoint where the two planes of a roof meet to form a seam. In currentroofing installation, a flashing material is usually installed in thisseam area to protect the underlying roof structure from water drainage.However, this technique does not combat negative pressure effects.

The subject invention utilizes a grout or mortar based material withsufficient strength to withstand environmental conditions, extreme orotherwise, to seal this area. With the tile panel system andinstallation of the subject invention, this will provide a roof sealedand protected from the elements, and able to withstand extreme weatherand wind conditions.

EXAMPLE 6 Installation Method

The tile panels and associated specialized panels described above arepreferably installed in a standard overlapping fashion well-known in theart. The tile and other panels of the subject invention are similarlyinstalled. However, the interlock features for the panels provided withthe subject invention require an additional consideration wheninstalling the panels on a structure. The following installation methodillustrates use of the tile panels as a roof covering. However, it willbe understood by a person with skill in the art that this method can bemodified for installation on other structures.

After insuring that all underlayment, e.g., support structures,flashing, etc., are installed, it is necessary to next determine thestarting point for laying the first tile(s). In a preferred embodiment,the panels of the subject invention are designed to be installedstarting from one of the lower edges of a roof. In a further preferredembodiment, the interlock features are designed so that the panels areinstalled starting from the right side of one of the lower edges of aroof.

After determining the appropriate starting point, the first tile panelshould be placed against the support structure, e.g., roof decking, todetermine whether it needs to be cut to accommodate the shape of theroof area to be covered. If necessary, the tile should be cut so thatthe angle of the cut is flush with roof edge against which it will beplaced, whether it is a roof valley, hip, or gable end.

In this installation, the tile panels 10 are interconnected with thedrip edge panels 40 along the edge of the roof line. Therefore, theinitial tile panel 10 should be placed so as to determine where theassociated drip edge panel 40 must also be placed. Once this has beendetermined and the positions fixed for the initial drip edge panel 40,all of the additional drip edge panels can be installed along the roofedge using, preferably, an adhesive as well as nails or screws to holdthem in place.

The tile panels 10 can then be installed starting against the drip edgepanels 40, from the right side all the way to the left side of the roof,preferably using an adhesive along with nails or screws to secure thetile panels in place. The second row of tile panels 10 is also startedalong the right side of the roof. It is further preferable for the seamof the tile panels 10 in the first row to be situated in the middle ofthe tile panel of the second, overlapping row of tile panels 10, tocreate a staggered tile pattern. Therefore, as mentioned above, if it isnecessary to cut the tile panel 10, the cut should match as close aspossible the angle of the roof edge against which it will be placed,whether it is a roof valley, hip, or gable end. As an example, if thestarting point is a roof valley, it is preferable to leave no more thanapproximately 1″ between the tile panel and the valley edge. In the caseof a hip or gable starting point, it is preferable for the tile panelsto almost touch the hip or gable beam on which the hip panel and gablepanels will later be installed.

Tile panels 10 can continue to be installed in this fashion across theroof until the final row along the roof ridge. At this point, it may benecessary to cut the tile panels 10 so that they cover the roof line andalmost touch the roof ridge beam on which the crown panels will later beinstalled. It may also be necessary to drill or otherwise create holesin the tile panels 10 along the roof ridge line, if the ends with themounting holes 14 must be cut away to accommodate the roof ridge beam.Once the entire roof surface has been covered with the tile panels 10,the hip, gable and ridge crown panels can be installed where necessary.

The hip panels 60 are installed beginning from the bottom edge of theroof hip so the panels can be properly attached using the nails orscrews before the subsequent hip panel is installed to overlap the firstone. Again, it is preferable to use an adhesive along with the nails orscrews to secure the hip panels against the beam. Once the first hippanel is in place and secured, subsequent hip panels can be installedusing the locking tracks 64 to place and secure the hip panels againstthe beam and the interlock channel 66 to connect and secure the hippanels in an end-to-end and overlapping fashion along the roof hip line.All of the hip panels 60 should be installed in this fashion.

The gable panels 70 are installed similarly to the hip panels 60beginning from the bottom edge of the roof gable line so they can beproperly secured, preferably with an adhesive and nails or screws, andoverlapped. As described above, gable panels 70 have an elongatedoutside edge 78 which should be positioned over the edge of the roofgable line to facilitate water drainage away from the roof andstructure. Gable panels are positioned on a beam utilizing a lockingtrack 74, similar to the hip panels, and they interlock using aninterlock channel 76.

Once the hip 60 and gable panels 70 have been installed, the crownpanels 50 are used to close and seal the roof ridge. In a preferredmethod, installation of the crown panels 50 begins on the left side ofthe roof line, with the groove 54 end towards the right side of the roofline. Thus, the crown panels 50 are installed in a left to right fashionusing the locking track 58 to place and secure the crown panels with thetongue 56 of one crown panel seated in the groove 54 of the adjacentcrown panel 50. Again, it is preferable to use an adhesive along withnails or screws to secure the crown panels.

The final step is to seal off the valley seams and the ends of the hip,gable or crown panels. Specialized caps as described above can be usedto close the ends of the hip, gable or crown panels. Alternatively, orin addition, grout, cement or similar material can be used to seal theseareas, as well as any valley seams. In addition, it is customary andpreferable to further seal all open areas between the panels 10 and anyhip 60, gable 70, or crown 50 panels to resist intrusion of wind orwater under the roof system.

II. Tenon and Mortise Interlock Tile Panel

With regard to the above description of the overlap interlocking tilepanels, an alternative embodiment utilizes a tenon and mortise (alsocalled a tongue-and-groove) interlock system. An example of thisselectively interlocking embodiment can be seen in FIGS. 12A and 12B.

This embodiment utilizes a tenon and mortise interlock system 90,wherein at least one tenon 92 is formed on the bottom side 24 at or nearat least one edge of a tile panel 10 and at least one congruously shapedmortise 94 is formed into at least one other edge of the tile. In apreferred embodiment, the at least one tenon 92 is formed as part of theleading edge 150 of a tile and the mortise 94 is formed as part of thetrailing edge 300 of a tile.

A mortise and tenon of the subject application may utilize a variety ofshapes capable of being operably engaged or interlocked. In a preferredembodiment, the shape and/or configuration of the tenon and mortise willenable the tenon 92 to be engaged with the mortise 94 by sliding thetenon into the mortise. In a still further preferred embodiment, thetenon 92 and mortise 94 are formed in a dove-tail configuration,wherein, the tenon 92 is flared such that the base 97 that engages withthe mortise 94 is wider than the apex 98 that intersects and fixedlyconnects with the bottom side 24 of the tile. Such a configuration iswell-known in the art and a person with skill in the art will be able todetermine the appropriate angle of flare required for the materialsutilized for a sheathing surface 12.

A corresponding groove or mortise 94 can be formed as part of at leastone other edge of a tile, where the circumferential shape of the mortise94 corresponds to the circumferential shape of the at least one tenon92, for example, as shown in FIGS. 12A and 12B. In a preferredembodiment, the dimensions of a mortise 94 are sufficiently larger thanthe dimensions of a tenon 92 to ensure that they can be fit togetherwith general ease without damage to the tile panel 10 or havingexcessive space for movement or play between the sides of the tenon andthe sides of the mortise.

In one embodiment, a tile panel 10 has at least one tenon 92 positionedat the leading edge 150, but offset from the center line 500 between theleading edge 150 and the trailing edge 300. A corresponding at least onemortise 94 is positioned at the trailing edge 300 of the tile and isoffset from the longitudinal center line 500 to the opposite side of thetile as the tenon 92. Thus, when the tenon of a first tile is insertedinto the mortise of a second tile the tiles will be offset permitting astaggered pattern when numerous tiles are connected.

A preferred embodiment utilizes a modified dove-tail configuration. Inthis embodiment, a tile panel 10 has one tenon 92 centered at theleading edge 150. A correspondingly shaped mortise 94 is divided betweenthe comer edges 99 of the trailing edge 300 of the tile, such that afirst side of a mortise 95 is formed at one comer edge 99 of the tilepanel and a mirror-image thereof forms the second side of a mortise 96at the opposite comer edge of the tile panel. In this embodiment, acomplete mortise 94 is formed by two separate tiles, such that when twotiles are positioned side-by-side, with the trailing edges 300 beingsubstantially co-planar, the combined comer edges define a full mortise94.

In a preferred embodiment, when a tenon is interlocked with a mortise,the tiles will preferably be arranged in a staggered and overlappingconfiguration. In a further preferred embodiment, to maintain theirinterlocking overlapped positions, the tile panels can be furtheraffixed to a roof decking via techniques and device discussed above. Theability to interlock the leading edges 150 with the trailing edges 300and by further affixing the tiles to a roof decking or other structureensures that wind-lifting of the tiles, even in extreme weather andhigh-wind conditions will be reduced or eliminated.

III. Tile Bracket

A further alternative embodiment provides a tile bracket apparatus thatcan be incorporated into existing tiles or even certain embodiments ofthe tile panels of the subject invention. With regard to FIG. 13A, itcan be seen that an embodiment of a tile bracket 600 of the subjectinvention is fixedly attached to a tile using a flange 610. The flangecan be incorporated into a tile at the time of manufacture or affixed tothe tile by a variety of techniques after manufacture, such as forexample, with adhesives, screws, nails, bolts, combinations thereof,etc. For certain tile types, the tile brackets 610 of the subjectinvention could even be fixedly attached onto tiles already installed ona structure. FIG. 13A shows an example of a tile bracket that can beincorporated into the tile material. FIG. 13B shows an example of a tilebracket that can affixed to a tile by alternative techniques.

A bracket arm 615 is affixed to the flange 610 and extends generallyperpendicularly from the flange 610. The bracket arm 615 can extend fromthe flange 610 to any desirable height. However, in a preferredembodiment, the height of the bracket arm 615 will correspond to thethickness of the tile panels with which it will be used. Fixedlyconnected to the bracket arm 615 is a tile stop 620 that extendsgenerally perpendicularly from that end of the bracket arm 615 oppositethe flange 610. The tile stop 620 is directed towards the trailing edge300 of a tile and along with the bracket arm 615 forms a notch 630 intowhich the leading edge 150 of an overlapping tile panel 10 can beplaced.

When the leading edge 150 of a tile or a tile panel of the subjectinvention is positioned within the notch 630, the bracket arm 615prevents the tile from changing position and the tile stop 620 preventswind-lift of the leading edge. The tile panels can be further affixed tothe roof decking 16 or other underlying structure by procedures andmethods discussed above to provide further protection against wind-liftand/or repositioning of the tiles.

In a preferred embodiment, at least one tile bracket 600 is affixedapproximately 3 inches to approximately 5 inches from the trailing edge300 of a tile. This allows the tiles to be overlapped when positionedwithin the tile brackets 600.

The tile brackets 600 can comprise any of a variety of materials havingthe necessary resistance to environmental conditions, including, forexample, various metals, plastics, ceramics, clay, cement, wood, orcomposites thereof, etc. In addition, the tile bracket 600 or componentsthereof can embody any desired decorative features. For example, thetile brackets can be any of a variety of colors to complement and/orblend with the tiles or tile panels with which they are utilized, andthe bracket arm 615 and/or the tile stop 620 can further embody anydesired shape. In one embodiment, the tile brackets 600 are aluminum andthe tile stop 620 is formed as a flattened flange 650 that can lie flushwith the top surface 26 of a tile, as shown for example in FIG. 13B.

In further alternative embodiments of the tile bracket 600 of thesubject invention, any of an assortment of accessories can be affixed toor formed as part of the tile bracket. For example, snow guards arewell-known in snowy climates. Therefore, in one alternative embodiment,snow guards can be incorporated into the tile brackets of the subjectinvention. By way of example, the tile stop 620 of a tile bracket 600could be modified to include a snow guard apparatus. It is alsowell-known in the art to decorate snow guards with various shapes,motifs, styles, colors, and to adjust the angles, widths, etc., toaccommodate various expected snowfall amounts. Such decorative oradjustable features could also be used with the snow guards incorporatedinto the tile brackets 600 of the subject invention.

A further alternative embodiment can incorporate various blades, vanesor fins for controlling the absorption of thermal energy. It iswell-known in the art to utilize various materials to absorb heat andre-direct it away from an underlying structure, such as a roof. Thus,the tile brackets 600 of the subject invention could incorporatecomponents for absorbing thermal heat and dissipating it into thesurround environment. For example, various shaped projections, fins,rods, etc. could extend from the bracket arm 615 and/or the tile stop620.

All patents, patent applications, provisional applications, andpublications referred to or cited herein are incorporated by referencein their entirety, including all figures and tables, to the extent theyare not inconsistent with the explicit teachings of this specification.

It should be understood that the examples and embodiments describedherein are for illustrative purposes only and that various modificationsor changes in light thereof will be suggested to persons skilled in theart and are to be included within the spirit and purview of thisapplication.

1. A wind-resistant interlocking tile panel comprising: a sheathingsurface having a top side, a bottom side, a leading edge, and a trailingedge, wherein the leading edge of a first such tile panel is capable ofoverlapping a trailing edge of an adjacent second such tile panel when aportion of the bottom side at the leading edge of the first tile panelis positioned over a portion of the top side at the trailing edge of thesecond tile panel; backing material connected to at least a portion ofthe bottom side of the sheathing surface; and an interlock channel alongthe leading edge, the interlock channel configured such that when theleading edge of the first tile panel is positioned to overlap thetrailing edge of the second tile panel, a portion of the second tilepanel engages the interlock channel of the first tile panel and backingmaterial at the leading edge of the first tile panel abuts backingmaterial at the trailing edge of the second tile panel.
 2. The tilepanel according to claim 1, wherein at least a portion of the interlockchannel is defined by the backing material.
 3. The tile panel accordingto claim 1, wherein the sheathing surface comprises a material selectedfrom the group consisting of metals, clays, concretes, plastics, glass,woods, natural or petroleum-based products, and combinations of any ofthe foregoing.
 4. The tile panel according to claim 1, wherein thesheathing surface comprises a material selected from the groupconsisting of lightweight concrete, cellular concrete, and lightweightaggregate concrete.
 5. The tile panel according to claim 1, wherein thebacking material is offset from the leading edge, so that some portionof the bottom side of the sheathing surface at the leading edge extendsbeyond the backing material.
 6. The tile panel according to claim 1,wherein the sheathing surface at the trailing edge of the second tilepanel engages the interlock channel of the first tile panel.
 7. The tilepanel according to claim 1, wherein the backing material is offset fromthe trailing edge, so that some portion of the bottom side of thesheathing surface at the trailing edge extends beyond the backingmaterial.
 8. The tile panel according to claim 7, wherein the sheathingsurface at the trailing edge of the second tile panel engages theinterlock channel of the first tile panel.
 9. The tile panel accordingto claim 5, wherein the backing material is offset from the trailingedge, so that some portion of the bottom side of the sheathing surfaceat the trailing edge extends beyond the backing material.
 10. The tilepanel according to claim 9, wherein the sheathing surface at thetrailing edge of the second tile panel engages the interlock channel ofthe first tile panel.
 11. The tile panel according to claim 1, having awidth, measured from the leading edge to the trailing edge, ofapproximately 1.5 feet and a length, measured from each side, ofapproximately 4 feet.
 12. The tile panel according to claim 1, furthercomprising one or more mounting holes.
 13. The tile panel according toclaim 12, wherein said mounting holes are at an angle of approximately40° to approximately 75°, relative to the support surface.
 14. The tilepanel according to claim 1, wherein the sheathing surface is in abarrel-style formation.
 15. The tile panel according to claim 1, whereinthe sheathing surface is in a flat-tile formation.
 16. The tile panelaccording to claim 1, wherein the backing material comprises plastics,woods, metals, lightweight concretes, ceramics, clays, foams, orcombinations or composites thereof.
 17. The tile panel according toclaim 1, wherein the backing material comprises a foam.
 18. The tilepanel according to claim 17, wherein the foam is a rigid and closed-cellmaterial.
 19. A wind-resistant interlocking crown tile panel comprising:an elongated sheathing surface having a top side, a bottom side, aleading edge having a collar on the bottom side, and a trailing edgehaving a groove on the top side; and backing material connected to atleast a portion of the bottom side of the sheathing surface and fillingat least a portion of the space around a locking track, the lockingtrack extending lengthwise along the bottom side of the crown panel; thecrown panel configured such that when the bottom side of the leadingedge of a first such crown panel is overlapping the top side of thetrailing edge of an adjacent second such crown panel, the collar of thefirst crown panel is positioned in the groove of the second crown panel.20. The crown tile panel according to claim 19, wherein the lockingtrack is defined by the backing material.
 21. The crown tile panelaccording to claim 19, wherein the locking track is molded into thesheathing surface.
 22. The crown tile panel according to claim 19,wherein the locking track is at least partially defined by material thatis different from the backing material, and that is incorporated intothe crown panel.
 23. The crown tile panel according to claim 19, whereina portion of the backing material extends forward at the leading edge soas to be received under the trailing edge of an adjacent second suchcrown panel when the collar of the first such crown panel is positionedin the groove of the second such crown panel.
 24. The crown tile panelaccording to claim 19, wherein a portion of the locking track extendsslightly forward at its leading edge so as to be received under thetrailing edge of an adjacent second such crown panel when the collar ofthe first such crown panel is positioned in the groove of the secondsuch crown panel.
 25. A wind-resistant drip edge panel comprising: aleading edge guard having a frontside and a backside; at least oneinterlock flange connected to and extending away from the backside ofthe leading edge guard; and a drip edge fixedly attached to andextending away from the frontside of the leading edge guard.
 26. Thedrip edge panel according to claim 25, further comprising a singleinterlock flange extending along at least a portion of the backside ofthe leading edge guard.
 27. The drip edge panel according to claim 25,further comprising a plurality of interlock flanges positioned along thebackside of the leading edge guard.
 28. A wind-resistant interlockinghip tile panel comprising: an elongated sheathing surface having a topside, a bottom side, a leading edge, and a trailing edge, wherein theleading edge of a first such hip tile panel is capable of overlapping atrailing edge of an adjacent second such hip tile panel when a portionof the bottom side at the leading edge of the first hip tile panel ispositioned over a portion of the top side at the trailing edge of thesecond hip tile panel; backing material connected to at least a portionof the bottom side of the sheathing surface and filling at least aportion of the space around a locking track, the locking track extendinglengthwise along the bottom side of the hip panel; and an interlockchannel along the leading edge, the interlock channel configured suchthat when the leading edge of the first hip tile panel is positioned tooverlap the trailing edge of the second hip tile panel, a portion of thesecond hip tile panel engages the interlock channel of the first hiptile panel.
 29. The hip tile panel according to claim 28, wherein atleast a portion of the interlock channel is defined by the backingmaterial, the interlock channel configured such that when the leadingedge of the first hip tile panel is positioned to overlap the trailingedge of the second hip tile panel, a portion of the second hip tilepanel engages the interlock channel of the first tile panel and backingmaterial at the leading edge of the first hip tile panel abuts backingmaterial at the trailing edge of the second hip tile panel.
 30. The hiptile panel according to claim 28, wherein the backing material is offsetfrom the leading edge, so that some portion of the bottom side of thesheathing surface at the leading edge extends beyond the backingmaterial.
 31. The hip tile panel according to claim 28, wherein thesheathing surface at the trailing edge of the second hip tile panelengages the interlock channel of the first hip tile panel.
 32. The hiptile panel according to claim 28, wherein the backing material is offsetfrom the trailing edge, so that some portion of the bottom side of thesheathing surface at the trailing edge extends beyond the backingmaterial.
 33. The hip tile panel according to claim 32, wherein thesheathing surface at the trailing edge of the second hip tile panelengages the interlock channel of the first hip tile panel.
 34. The hiptile panel according to claim 30, wherein the backing material is offsetfrom the trailing edge, so that some portion of the bottom side of thesheathing surface at the trailing edge extends beyond the backingmaterial.
 35. The hip tile panel according to claim 34, wherein thesheathing surface at the trailing edge of the second hip tile panelengages the interlock channel of the first hip tile panel.
 36. The hiptile panel according to claim 28, wherein the locking track is definedby the backing material.
 37. The hip tile panel according to claim 28,wherein the locking track is molded into the sheathing surface.
 38. Thehip tile panel according to claim 28, wherein the locking track is atleast partially defined by material that is different from the backingmaterial and that is incorporated into the crown panel.
 39. Awind-resistant interlocking gable tile panel comprising: an elongatedsheathing surface having a top side, a bottom side, an outside edge, aninside edge, a leading edge, and a trailing edge, wherein the leadingedge of a first such gable tile panel is capable of overlapping atrailing edge of an adjacent second such gable tile panel when a portionof the bottom side at the leading edge of the first gable tile panel ispositioned over a portion of the top side at the trailing edge of thesecond gable tile panel; backing material connected to at least aportion of the bottom side of the sheathing surface and filling at leasta portion of the space around a locking track, the locking trackextending lengthwise along the bottom side of the gable panel; aninterlock channel along the leading edge, the interlock channelconfigured such that when the leading edge of the first gable tile panelis positioned to overlap the trailing edge of the second gable tilepanel, a portion of the second gable tile panel engages the interlockchannel of the first gable tile panel; and wherein the outside edge ofthe sheathing surface extends lower than the inside edge of thesheathing surface when the panel is viewed end-on with the lockingchannel in a lengthwise-horizontal perspective.
 40. An interlocking rooftile panel system comprising: a plurality of tile panels, eachcomprising a sheathing surface having a top side, a bottom side, aleading edge, and a trailing edge, wherein the leading edge of a firstsuch tile panel is capable of overlapping a trailing edge of an adjacentsecond such tile panel when a portion of the bottom side at the leadingedge of the first tile panel is positioned over a portion of the topside at the trailing edge of the second tile panel; backing materialconnected to at least a portion of the bottom side of the sheathingsurface; an interlock channel along the leading edge, the interlockchannel configured such that when the leading edge of the first tilepanel is positioned to overlap the trailing edge of the second tilepanel, a portion of the second tile panel engages the interlock channelof the first tile panel and backing material at the leading edge of thefirst tile panel abuts backing material at the trailing edge of thesecond tile panel; a plurality of drip edge panels, each comprising aleading edge guard having a frontside and a backside; at least oneinterlock flange connected to and extending away from the backside ofthe leading edge guard; a drip edge fixedly attached to and extendingaway from the frontside of the leading edge guard; a plurality of hiptile panels each comprising an elongated sheathing surface having a topside, a bottom side, a leading edge, and a trailing edge, wherein theleading edge of a first such hip tile panel is capable of overlapping atrailing edge of an adjacent second such hip tile panel when a portionof the bottom side at the leading edge of the first hip tile panel ispositioned over a portion of the top side at the trailing edge of thesecond hip tile panel; backing material connected to at least a portionof the bottom side of the sheathing surface and filling at least aportion of the space around a locking track, the locking track extendinglengthwise along the bottom side of the hip panel; an interlock channelalong the leading edge, the interlock channel configured such that whenthe leading edge of the first hip tile panel is positioned to overlapthe trailing edge of the second hip tile panel, a portion of the secondhip tile panel engages the interlock channel of the first hip tilepanel; and a plurality of crown tile panels, each comprising anelongated sheathing surface having a top side, a bottom side, a leadingedge having a collar on the bottom side, and a trailing edge having agroove on the top side; backing material connected to at least a portionof the bottom side of the sheathing surface and filling at least aportion of the space around a locking track, the locking track extendinglengthwise along the bottom side of the crown panel; the crown panelconfigured such that when the bottom side of the leading edge of a firstsuch crown panel is overlapping the top side of the trailing edge of anadjacent second such crown panel, the collar of the first crown panel ispositioned in the groove of the second crown panel; wherein theinterlock flanges of the drip edge panels are complimentarily configuredso as to engage an interlock channel along the leading edge of one ormore tile panels.
 41. The roof tile panel system according to claim 40,further comprising: a plurality of gable tile panels, each comprising anelongated sheathing surface having a top side, a bottom side, an outsideedge, an inside edge, a leading edge, and a trailing edge, wherein theleading edge of a first such gable tile panel is capable of overlappinga trailing edge of an adjacent second such gable tile panel when aportion of the bottom side at the leading edge of the first gable tilepanel is positioned over a portion of the top side at the trailing edgeof the second gable tile panel; backing material connected to at least aportion of the bottom side of the sheathing surface and filling at leasta portion of the space around a locking track, the locking trackextending lengthwise along the bottom side of the gable panel; aninterlock channel along the leading edge, the interlock channelconfigured such that when the leading edge of the first gable tile panelis positioned to overlap the trailing edge of the second gable tilepanel, a portion of the second gable tile panel engages the interlockchannel of the first gable tile panel; and wherein the outside edge ofthe sheathing surface extends lower than the inside edge of thesheathing surface when the panel is viewed end-on with the lockingchannel in a lengthwise-horizontal perspective.
 42. A wind-resistantinterlocking tile panel comprising: a sheathing surface having a topside, a bottom side, a leading edge, a trailing edge, and a mountinghole proximal to the trailing edge, the trailing edge being above themounting hole, wherein the leading edge of a first such tile panel iscapable of overlapping a trailing edge and mounting hole of an adjacentsecond such tile panel when a portion of the bottom side at the leadingedge of the first tile panel is positioned over a portion of the topside at the trailing edge of the second tile panel; backing materialconnected to at least a portion of the bottom side of the sheathingsurface; and means for interlocking said leading edge with the trailingedge of an adjacent second tile panel wherein when the leading edge ofthe first tile panel is positioned to interlock with the trailing edgeof the adjacent second tile panel, the means for interlocking is locatedabove the mounting hole of the second tile panel.
 43. The tile panelaccording to claim 42, wherein the means for interlocking comprises atenon extending from the leading edge and a mortise at the trailing edgeof a tile panel, such that when the tenon of a first such tile panel isengaged with the mortise of an adjacent second such tile panel, aportion of the leading edge of the first tile panel will overlap thetrailing edge of the second tile panel.
 44. The tile panel according toclaim 43, wherein the means for interlocking further comprises a partialmortise at each comer of the trailing edge, such that when two of thetile panels are placed side by side, the trailing edge corners that abutone another form a mortise at the point where the trailing edges of thetwo panels meet.
 45. The tile panel according to claim 42, wherein themeans for interlocking comprises a mortise at the leading edge and atenon extending from the trailing edge, such that when the mortise of afirst such tile panel is engaged with the tenon of an adjacent secondsuch tile panel, a portion of the leading edge of the first tile panelwill overlap the trailing edge of the second tile panel.
 46. The tilepanel according to claim 42, wherein the means for interlockingcomprises an interlock channel along the leading edge, the interlockchannel configured such that when the leading edge of the first tilepanel is positioned to overlap the trailing edge of the second tilepanel, a portion of the second tile panel engages the interlock channelof the first tile panel.
 47. The tile panel according to claim 46,wherein at least a portion of the interlock channel is defined by thebacking material.